TOOL NEWS B065A 2013.4 Update Optimum tool for finish machining High accuracy like Solid Carbide End Mills. High accuracy insert positioning and high rigidity clamping. Significant reduction in tool costs for finishing. High accuracy indexable end mill SUFT Insert SRFT Insert SUFT Insert SRFT Insert New Insert EP6120 Grade Indexable Ball-nose & Corner Radius End Mill for Finishing SRF
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TOOL NEWS B065A2013.4 Update
Optimum tool forfi nish machiningHigh accuracy like Solid Carbide End Mills.High accuracy insert positioning and high rigidity clamping.Signifi cant reduction in tool costs for fi nishing.
High accuracy indexable end mill
SUFT Insert
SRFT Insert
SUFT Insert
SRFT Insert
New Insert
EP6120 Grade
Indexable Ball-nose & Corner Radius End Mill for Finishing
The smooth twist in the edge geometry achieves an excellent balance of sharpness and cutting edge strength. Highly accurate grinding is used to produce seamless peripheral, corner and bottom edges.
Short peripheral cutting edge to reduce vibration when wall machining.
MIRACLE coated VP15TF has a good balance of wear and chipping resistance. MP8010 demonstrates outstanding cutting performance when machining hardened steel and cast iron.
SUF inserts can also be used in a wide range of SRF tool bodies.
Insert
Insert gradesAccurate tolerance
Compatibility
Finishing of molds(Metric) R0.5 , R1 , R2 , R3
Features
Hardened steels Cast iron45HRC 65HRC
Wiper edge
Seamless Gash
Peripheral cutting edgeWiper edge geometry provides excellent surface fi nishes even when the feedrate is increased.
SRFT0375 a a a .375 .1875 ─ .335 .020 .102 ─0500 a a a .500 .2500 ─ .394 .020 .118 ─0625 a a a .625 .3125 ─ .472 .039 .158 ─0750 a a a .750 .3750 ─ .591 .039 .197 ─1000 a a a 1.000 .5000 ─ .728 .039 .236 ─1250 a a a 1.250 .6250 ─ .925 .039 .276 ─
MP
8010
EP61
20V
P15
TF
D1 R Re L1 F1 S1 ap
SRFT10 s s s 10 5 (.1969") ─ 8.5 0.5 2.6 ─12 s s s 12 6 (.2362") ─ 10 0.5 3 ─16 s s s 16 8 (.3150") ─ 12 1 4 ─20 s s s 20 10 (.3937") ─ 15 1 5 ─25 s s s 25 12.5 (.4921") ─ 18.5 1 6 ─30 s s s 30 15 (.5906") ─ 22.5 1 7 ─32 s s s 32 16 (.6299") ─ 23.5 1 7 ─
SUFT10R05 s s s 10 ─ 0.5 (.0197") 8.5 1 2.6 1.510R10 s s s 10 ─ 1 (.0394") 8.5 1 2.6 210R20 s s s 10 ─ 2 (.0787") 8.5 1 2.6 312R05 s s s 12 ─ 0.5 (.0197") 10 1.2 3 1.712R10 s s s 12 ─ 1 (.0394") 10 1.2 3 2.212R20 s s s 12 ─ 2 (.0787") 10 1.2 3 3.212R30 s s s 12 ─ 3 (.1181") 10 1.2 3 4.216R05 s s s 16 ─ 0.5 (.0197") 12 1.6 4 2.116R10 s s s 16 ─ 1 (.0394") 12 1.6 4 2.616R15 s s s 16 ─ 1.5 (.0591") 12 1.6 4 3.116R20 s s s 16 ─ 2 (.0787") 12 1.6 4 3.616R30 s s s 16 ─ 3 (.1181") 12 1.6 4 4.620R05 s s s 20 ─ 0.5 (.0197") 15 2 5 2.520R10 s s s 20 ─ 1 (.0394") 15 2 5 320R15 s s s 20 ─ 1.5 (.0591") 15 2 5 3.520R20 s s s 20 ─ 2 (.0787") 15 2 5 420R30 s s s 20 ─ 3 (.1181") 15 2 5 525R05 s s s 25 ─ 0.5 (.0197") 18.5 2.5 6 325R10 s s s 25 ─ 1 (.0394") 18.5 2.5 6 3.525R20 s s s 25 ─ 2 (.0787") 18.5 2.5 6 4.525R30 s s s 25 ─ 3 (.1181") 18.5 2.5 6 5.530R05 s s s 30 ─ 0.5 (.0197") 22.5 3 7 3.530R10 s s s 30 ─ 1 (.0394") 22.5 3 7 430R20 s s s 30 ─ 2 (.0787") 22.5 3 7 530R30 s s s 30 ─ 3 (.1181") 22.5 3 7 632R05 s s s 32 ─ 0.5 (.0197") 23.5 3.2 7 3.732R10 s s s 32 ─ 1 (.0394") 23.5 3.2 7 4.232R20 s s s 32 ─ 2 (.0787") 23.5 3.2 7 5.2
S1F1 ap L1±0
.015
Re±0.010
D1-0.02
0 0
F1L1
±0.0
15
R±0.006
S1
D1–0.02
7 0
F1L1
±.00
06"
R±.00024"
S1
D1–.001
1" 0
Indexable Ball-nose & Corner Radius End Mill for Finishing
INSERTS
METRIC Standard
INCH Standard
Shape
Shape
Coated
Coated
Geometry
Geometry
Dimensions (inch)
Dimensions (mm)
Order Number
Order Number
a : Inventory maintained. s : Inventory maintained in Japan. <2 inserts in one case>
12
P 180HB EP6120 655 (260─985) .008 (.004─ .012) < 0.05D1
Recommended Cutting Conditions for SRFT Ball-nose inserts
(Note 1) The values above are for average machining conditions. The optimum values can change slightly according to the condition and rigidity of the machine and work holding. Adjust the values accordingly.(Note 2) For end mills with a carbide shank, up to 20 percent higher cutting conditions are possible.(Note 3) Please note the following when machining hardened steel with MP8010. • Please shorten the overhang length as much as possible. • Use with carbide shank recommended. • Take special care with the depth of cut to prevent fracture.
Work Material Hardness Insert GradesCutting Speed
vc(SFM)
Feed per Toothfz
(IPT)
Depth of Cutap
(inch)
Mild Steel
Carbon SteelAlloy Steel
Pre-hardened steels
Alloy Tool Steel
Gray Cast Iron
Ductile Cast Iron
Copper,Copper Alloys
Hardened Steel
13
vc =
Pf =
h =
øD1
Effectivecutting diameter
ap
Pf
h
Indexable Ball-nose & Corner Radius End Mill for Finishing
Calculating Actual Cutting Speed
Selecting Pick Feed
Insert Installation
2. Using ap Calculate cutting speed at the depth of cut line.
Theoretical h : Cusp heightpf : Pick feedR : Ball nose or corner radius
Actual surface roughness Rz will be about 3 times worse than theoretical h.This is because of the effect of a built-up edge.To determine Pf, use the formula below based on a particular Rz value.
1. Clean the insert and the insert pocket
2. Fitting the insert
Thoroughly clean the insert and the insert pocket on the holder body.
Place the concave mark on the insert uppermost as shown with the clamp screwinserted from above. Fasten the clamp screw while firmly pressing the insertagainst the insert pocket wall. Use of a special anti seize lubricant MK1KS is recommended. Tighten at the recommended torque range.
Concave mark
D1 : Tool diameter (inch)ap : Depth of Cut (inch)
1. Effective cutting diameter = 2 ap (D1-ap)
Effectivecutting diameter
vc : Actual cutting speed (SFM)n : Revolution (min-1)
Recommended Cutting Conditions for SUFT Corner Radius insertShoulder milling(When small width of cut.*)
Slot milling / Shoulder milling(When large width of cut.*)* When the pick feed direction is along the axis of the tool such as fi nish machining at the wall part.
(Note 1)This cutting condition is the standard condition when using the steel standard shank type. If vibration or chipping on cutting edge occurs, please decrease the cutting condition as width of cut, depth of cut and feed per tooth depending on the situation. (Note 2)Recommended cutting speeds apply to tool outside diameter. Please calculate the spindle speed of tool in the following expressions. Spindle speed of cutting tool n(min-1 )=12×Cutting speed vc ÷ Diameter of cutting tool D1 ÷ 3.14
Insert Installation
1. Clean the insert and insert pocketThoroughly clean the insert and the insert pocket on the holder body.
2. Fitting the insertPlace the concave mark on the insert uppermost as shown with the clamp screw inserted from above. Fasten the clamp screw while firmly pressing the insert against the insert pocket wall. Use of a special anti seize lubricant MK1KS is recommended. Tighten at the recommended torque range.
Concave mark
Work Material Hardness Insert GradesCutting Speed
vc(SFM)
Depth of Cutap
(inch)
Wide of Cutae
(inch)
Feed per Toothfz
(IPT)
Work Material Hardness Insert GradesCutting Speed
vc(SFM)
Depth of Cutap
(inch)
Wide of Cutae
(inch)
Feed per Toothfz
(IPT)
Carbon SteelAlloy Steel
Pre-hardened steels
Alloy Tool Steel
Stainless Steel
Cast Iron
Ductile Cast Iron
Hardened Steel
Hardened Steel
Carbon SteelAlloy Steel
Pre-hardened steels
Alloy Tool Steel
Stainless Steel
Cast Iron
Ductile Cast Iron
Hardened Steel
Hardened Steel
* When the pick feed direction is along the radius of the tool such as fi nish face machining.
15
M8 17.1 10M10 33.8 14M12 59.2 19M16 66.7 24
D9 D4 D5 L1 L2 H1 M
SC16M08S100S s 8.5 16 14.5 100 10 10 M8
08S200L s 8.5 16 14.5 200 10 10 M8
SC20M10S120S s 10.5 20 18.5 120 10 14 M10
10S220L s 10.5 20 18.5 220 10 14 M10
SC25M12S125S s 12.5 25 23.5 125 10 19 M12
12S245L s 12.5 25 23.5 245 10 19 M12
SC32M16S140S s 17 32 28.5 140 15 24 M16
16S280L s 17 32 28.5 280 15 24 M16
SC16M08S100SW s 8.5 16 14.5 100 10 10 M8
08S200LW s 8.5 16 14.5 200 10 10 M8
SC20M10S120SW s 10.5 20 18.5 120 10 14 M10
10S220LW s 10.5 20 18.5 220 10 14 M10
SC25M12S125SW s 12.5 25 23.5 125 10 19 M12
12S245LW s 12.5 25 23.5 245 10 19 M12
SC32M16S140SW s 17 32 28.5 140 15 24 M16
16S280LW s 17 32 28.5 280 15 24 M16
y
L2L1 H1
øD4
øD5
øD9
M
Indexable Ball-nose & Corner Radius End Mill for Finishing
HOW TO INSTALL THE SCREW-IN HEAD
a Cutting tools become extremely hot during cutting. Never touch them with bare hands after operation as this may produce risk of injuries or burns.
aDo not handle the cutting tools with bare hands as this may cause injuries.
z Thoroughly clean the clamp section of the head and the arbor with an air blower or brush before installation.x Tighten the head at the recommended torque and ensure that there is no gap between the head and arbor.
Die steel (33HRC) AISI D2(60HRC) AISI No40B AISI 4140(35HRC)
820 100-330 490-3080 61555 25 394 71
.007 .008 .012 .012
.008 .008 .008 .004
.047 .012 .020 .012
Indexable Ball-nose & Corner Radius End Mill for Finishing
APPLICATION EXAMPLESTool
InsertGrade
Machine Bridge-column machining center Vertical type M/C Bridge-column machining center Vertical type M/C
Work Material
Component Mold for forming resin Press mold Press mold Mold for forming resin
Cuttin
g Con
dition
s Actual Cutting Speed (SFM)Table Feed (IPM)Feed per Tooth (IPT)Depth of Cut (inch)Width of Cut (inch)
Coolant Water soluble Air blow Air blow Air blow
Results
Low cutting noise and good surface fi nish.
Higher effi ciency machining is achieved and the cutting t ime can be decreased compared with conventional PVD coated carbide.
Using the same cutting conditions as a conventional CBN grade, a cutting length of 32800 ft is achievable and also gives a surface fi nish quality equal to when CBN is used. The cost of cutting tools can be reduced.
The surface fi nish on the bottom face is improved compared to a conventional grade. VP15TF also achieved double tool life.
Memo
SRF
EXP-09-N084Printed in U.S.A. 05/13
For your safety aDon't touch breakers and chips without gloves. aPlease machine within recommended application range, and exchange expired tools with new parts in advance. aPlease use safety cover and wear safety glasses. aWhen using compounded cutting oils, please take fire prevention. aWhen attaching chips or spare parts, please use the attached wrench or spanner. aWhen using tools in revolution machining, please make a trial run to check run-out, vibration, abnormal sounds etc.
Mitsubishi Carbide Home page : (Tools specifications subject to change without notice.)
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